Manufacturing of Carbon Fibers/Polyphenylene Sulfide Composites via Induction-Heating Molding: Morphology, Mechanical Properties, and Flammability

Abstract

Conventional thermosetting composites exhibit advantageous mechanical properties owing to the use of an autoclave; however, their wide usage is limited by high production costs and long molding times. In contrast, the fabrication of thermoplastic composites involves out-of-autoclave processes that use press equipment. In particular, induction-heating molding facilitates a quicker thermal cycle, reduced processing time, and improved durability of the thermoplastic polymers; thus, the process cost and production time can be reduced. In this study, carbon fiber/polyphenylene sulfide thermoplastic composites were manufactured using induction-heating molding, and the relationships among the process, structure, and mechanical properties were investigated. The composites were characterized using optical and scanning electron microscopy, an ultrasonic C-scan, and X-ray computed tomography. In addition, the composites were subjected to flammability tests. This study provides novel insights into the optimization of thermoplastic composite manufacturing and thermoset composite curing processes.

Effect of Processing Parameters on Bonding Performance of a Carbon Fiber/Polyetheretherketone Thermoplastic Composite Prepared by Induction Welding

“…The heat treatment of the flat-panel specimens was performed by hot pressing at 380 • C for 30 min at a pressure of 9-50 bar, and cooling at 5 • C/min to room temperature. CF/PEEK composites with an average density of 1.55 g/cm 3 were obtained. In this manuscript, we will compare the morphology and mechanical behavior of two cases (Only AFP vs. AFP + hot press).…”

“…The void ratio obtained by acid digestion was determine using a minimum of three specimens from each composite part. The void ratio was calcu lated as follows: , mf is the mass of the fibers, ms the mass of the specimen, 𝝆 𝒔 is the specimen density, 𝝆 𝒓 is the matrix density (1.3 g/cm 3 ), and 𝝆 𝒇 is the fiber density (1.80 g/cm 3 ). Moreover, 𝝆 𝒔 was measured based o Archimedes' principle using distilled water following ASTM D 792 [41], which include the inner void structure.…”

“…is the mass of the fibers, m s is the mass of the specimen, ρ s is the specimen density, ρ r is the matrix density (1.30 g/cm 3 ), and ρ f is the fiber density (1.80 g/cm 3 ). Moreover, ρ s was measured based on Archimedes' principle using distilled water following ASTM D 792 [41], which includes the inner void structure.…”

“…Thermoplastic composites are effective alternatives to thermosetting matrix composites and can be used in various applications, because they can be easily processed without cutting and have a long lifespan, low storage cost, and high recyclability, as well as good impact resistance, heat resistance, and flame retardancy [1][2][3][4][5]. In recent years, composite materials for aircraft structures [6,7] have been predominantly manufactured using polypropylene and polyamide.…”